2007 BMW R 1200 Gs Fuel system Problems

When starting the bike, suddenly fuel started dripping down onto the front wheel and onto the exhaust. I noticed the fuel on the suction side (right side) of the gas tank pooling up and spraying out. Upon disassembly, the male 90 degree fuel quick disconnect (replacement part number BMW 13537674765) came apart when trying to release the hose from the female coupling. Replacing the connector and the clamp resolved the issue and fuel is no longer leaking. The last time this area was serviced was in 2014 when one of the other fuel tank recalls was completed and a reinforcement ring was installed on the flange at this location to prevent the flange itself from cracking, but in this instance it was the fitting itself. Called BMW motorcycles or Jacksonville (Florida ) and they indicated there is no warranty / recall/ service bulletin for this repair and I was able to purchase the part and perform the replacement.

NHTSA ID

11436242

Incident

Oct 8, 2021

THE FUEL PUMP ON THE MOTORCYCLE IS LEAKING AND SPRAYING GAS ALL OVER ME WHEN I DRIVE

NHTSA ID

11361069

Incident

Sep 5, 2020

Mileage

60,000 mi

AFTER STARTING THE BIKE AND ALLOWING IT TO WARM UP, I NOTICED A LARGE PUDDLE FORMING UNDER THE FRONT OF THE BIKE. UPON CLOSER INSPECTION I FOUND THE FUEL LINE QUICK CONNECT TO THE FUEL PUMP HAD SPLIT AND SPRAYING FUEL WHEN UNDER PRESSURE. THIS WAS DRIPPING DOWN ONTO THE HOT HEADER.

NHTSA ID

11309054

Incident

Feb 12, 2020

Mileage

11,000 mi

TL* THE CONTACT OWNS A 2007 BMW R1200 GS MOTORCYCLE. THE CONTACT STATED THAT THE FUEL STRIP FRACTURED AND HAD TO BE REPLACED MORE THAN THREE TIMES BY MORTON'S BMW MOTORCYCLES (540-891-9844, LOCATED AT 5099A JEFFERSON DAVIS HIGHWAY, FREDERICKSBURG, VIRGINIA 22408). THE DEALER STATED THAT THEY WOULD REPLACE THE FUEL STRIP PER SERVICE INFORMATION BULLETIN: 1600214(17) REGARDING THE FUEL STRIP BMW EXTENDED WARRANTY CAMPAIGN. THE MOTORCYCLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 13V617000 (FUEL SYSTEM, GASOLINE) AND TWO TSBS WERE ISSUED BY THE MANUFACTURER FOR THE FUEL SYSTEM. THE MANUFACTURER WAS CONTACTED. THE VIN AND FAILURE MILEAGE WERE NOT AVAILABLE.

NHTSA ID

11153312

Incident

Aug 1, 2016

TL* THE CONTACT OWNS A 2007 BMW R1200 GS MOTORCYCLE. WHILE THE VEHICLE WAS AT A STOP SIGN, THERE WAS AN ODOR OF FUEL AROUND THE VEHICLE. THE CONTACT LOOKED DOWN AND NOTICED FUEL ON HIS LEG, WHICH DRIPPED DOWN THE LEFT SIDE OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THERE WAS A CROCK FLANGE ON THE FUEL PUMP THAT NEEDED TO BE REPAIRED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 8,000.

NHTSA ID

10917633

Incident

Oct 2, 2016

Mileage

8,000 mi

TL* THE CONTACT OWNS A 2007 BMW R 1200 GS ADVENTURE. WHILE DRIVING APPROXIMATELY 20 MPH, THERE WAS AN ODOR OF FUEL AND FUEL FUEL LEAKED ON THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE VEHICLE WAS SERVICED PER NHTSA CAMPAIGN NUMBER: 13V617000 (FUEL SYSTEM, GASOLINE), BUT THE REMEDY FAILED TO REPAIR THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 26,000. THE VIN WAS NOT AVAILABLE. UPDATED 10/21/16*LJ *TR

NHTSA ID

10897569

Incident

Aug 19, 2016

Mileage

26,000 mi

FUEL PRESSURE CONTROL MODULE FAILED WITHOUT WARNING LEAVING ME STRANDED IN THE MIDDLE OF THE ROADWAY.

NHTSA ID

10775889

Incident

Sep 23, 2015

Mileage

44,738 mi

THE FUEL PUMP FLANGE ON THE HIGH-PRESSURE SIDE IS CRACKING AND LEAKING FUEL DUE TO A POOR DESIGN. PIPE-THREAD DESIGN IS CONTRIBUTING TO RADIAL CRACKS IN THE FLANGE CAUSING FUEL LEAKS. MACHINE THREADS WITH AN O-RING WOULD HAVE BEEN THE PROPER DESIGN. BMW HAS ADDRESSED THE PROBLEM IN LATER MODELS BY REINFORCING THE FLANGE WITH A METAL RING. THIS PROBLEM SHOULD BE ADDRESSED BY BMW. IT IS A POOR DESIGN UNDOUBTEDLY DRIVEN BY "VALUE ENGINEERING" CONCERNS RATHER THAN DEPENDABILITY OF A CRITICAL SYSTEM. *TR

NHTSA ID

10567434

Incident

Mar 5, 2014

Mileage

14,005 mi

FUEL STARTED LEAKING ON HOT EXHAUST WHILE RIDING ON THE FREEWAY. FURTHER INSPECTION REVEALED FUEL LEAKING FROM THE FUEL PUMP AREA. GAS APPEARS TO LEAK CONTINUOUSLY AND SPRAYS ON PANTS LEG. *TR

NHTSA ID

10549900

Incident

Oct 18, 2013

Mileage

19,250 mi

AFTER RIDING THE VEHICLE AND PUTTING IT BACK IN MY GARAGE, I COULD SMELL A STRONG GASOLINE ODOR. ON DETAILED INSPECTION I FOUND GAS POOLING IN THE "FUEL PUMP FLANGE". THIS PART IS LOCATED ON THE UPPER LEFT HAND SIDE OF THE FUEL TANK. AFTER CLEANING THE AREA, I COULD SEE DISTINCT CRACKS ALL AROUND THE FUEL LINE INLET AND GAS WOULD CONTINUOUSLY SEEP OUT OF THE CRACKS WHILE THE ENGINE WAS RUNNING. *TR

NHTSA ID

10542601

Incident

Sep 3, 2013

Mileage

20,500 mi

FUEL PUMP FLANGE ON TOP OF PUMP CRACKED AND GAS SPRAYED OUT AND RAN DOWN ON TO THE HOT EXHAUST PIPE. *TR

NHTSA ID

10537521

Incident

Aug 14, 2013

Mileage

15,125 mi

TL* THE CONTACT OWNS A 2007 BMW R 1200 GS MOTORCYCLE. THE CONTACT STATED THAT THE FUEL PUMP WAS LEAKING. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE. THE VEHICLE WAS NOT REPAIRED OR DIAGNOSED. THE FAILURE MILEAGE WAS APPROXIMATELY 47,000. UPDATED 10/29/13*LJ THE FLANG AT THE JOINT BETWEEN THE FUEL PUMP OUTPUT AND THE FUEL LINE, HAD A SPLIT, THUS ALLOWING FUEL TO LEAK AND RUN DOWN THE FRONT SIDE OF THE MOTORCYCLE THE EXHAUST HEADER. UPDATED 10/29/13

NHTSA ID

10536530

Incident

Aug 20, 2013

Mileage

47,000 mi

THE FUEL PUMP OUTLET QUICK CONNECTOR CRACKED, CAUSING GASOLINE TO LEAK OUT AND SPILL ALL OVER THE MOTORCYCLE CREATING A FIRE HAZARD AND POTENTIAL BRAKE FAILURE. ALSO THE GASOLINE SOAKED MY PANTS LEG CREATING ANOTHER FIRE HAZARD AND SKIN RASH. *TR

NHTSA ID

10535215

Incident

Jul 20, 2013

Mileage

22,715 mi

THE FUEL PUMP CASING/FLANGE IS CRACKED AND IS LEAKING FUEL. I THINK IT HAS BEEN GOING ON FOR A WHILE LONGER BUT I PREVIOUSLY DISCOUNTED THE GAS SMELL. *TR

NHTSA ID

10533377

Incident

Jul 17, 2013

Mileage

49,985 mi

THE PLASTIC FUEL PUMP FLANGE (PLATE THAT SEALS THE TOP OF THE FUEL TANK AND IS THE CONNECTIONS FOR THE FUEL PUMP) HAS DEVELOPED CRACKS IN THE "BOSS" FITTING FOR THE QUICK DISCONNECT HOSE FITTINGS. AFTER APPLYING A FIX FOR THIS, I'VE NOTICED WHAT APPEARS TO BE A HAIRLINE CRACK IN THE PLASTIC PLATE ITSELF, JUST BELOW THE METAL SCREW CAP RING. GAS WEEPS FROM THIS CRACK FAST ENOUGH TO FILL THE RECESS OF THE FUEL PUMP LID AND BEGINS DRIPPING DOWN THE INBOARD SIDE OF THE GAS TANK ONTO THE CYLINDER HEAD AND EXHAUST. FAILURE OF THE PARTS OF THE FUEL SYSTEM RESULTING IN LEAKS SHOULD BE ADDRESSED AS BOTH A POTENTIAL FIRE ISSUE, AS WELL AS A VERY SPECIFIC FUEL SPILLAGE/ENVIRONMENTAL ISSUE. *TR

NHTSA ID

10523626

Incident

Jun 10, 2013

Mileage

44,485 mi

NOTICED THE SMELL OF GASOLINE WHILE RIDING. TOOK THE MOTORCYCLE THE BMW DEALERSHIP THE NEXT DAY AND THEY FOUND CRACKING IN THE TOP FLANGE OF THE FUEL PUMP ASSEMBLY. THE MOTORCYCLE ONLY HAS 12000 MILES ON IT. AFTER SEARCHING THE INTERNET I FOUND THIS PROBLEM IS NOT UNCOMMON ON THIS MODEL. I BELIEVE THIS COULD BE A FIRE HAZARD WHICH COULD RESULT IN SEVERE INJURY OR DAMAGE. *TR

NHTSA ID

10509599

Incident

Apr 22, 2013

Mileage

12,000 mi

FUEL GAUGE/FUEL STRIP STOPPED WORKING PROPERLY. IT STARTED SHOWING A FULL TANK EVEN WHEN THE TANK WAS ALMOST EMPTY. SOMETIMES WILL SHOW AN EMPTY TANK WITH THE "LOW FUEL LIGHT" LIGHTING UP RANDOMLY, SOMETIMES EVEN WITH THE TANK FULL. THE FUEL GAUGE IS UNRELIABLE AND A CONSTANT DISTRACTION WHILE RIDING, A FAIRLY POSSIBLE HAZARDOUS ISSUE. THE FUEL GAUGE CANNOT BE DISCONNECTED, IT WILL MESS UP WITH THE ON BOARD COMPUTER. MULTIPLE BMW R1200GS OWNERS REPORTED VERBALLY AND IN WRITING THE SAME ISSUE WITH THE FUEL GAUGE FAILING EVEN IF REPLACED UNDER WARRANTY. THE BMW DEALERS AND CORPORATE REPRESENTATIVES ARE NOT COVERING THE FAULTY PART AFTER THE WARRANTY EXPIRES. PLEASE ADVISE. *TR

NHTSA ID

10502600

Incident

Jul 10, 2012

Mileage

14,000 mi

AS I WAS RIDING THE FUEL GAUGE WENT FROM SHOWING FULL TO SHOWING EMPTY IN LESS THAN 10 MILES. THE FUEL GAUGE CONTINUED TO SHOW THAT THE GAS TANK WAS EMPTY EVEN AFTER SUBSEQUENT FILL UPS. BMW REFUSED TO FIX THE FAULTY GAUGE OR FUEL STRIP AS MY BIKE WAS 38 MONTHS OLD EVEN THOUGH THIS IS A KNOW PROBLEM WITH BMW MOTORCYCLES. THIS PROBLEM I FEEL IS A SAFETY HAZARD AS IT MAY CAUSE THE BIKE TO RUN OUT OF GAS WITHOUT ANY WARNING. *TR

NHTSA ID

10499988

Incident

Feb 6, 2011

Mileage

31,400 mi

AFTER SMELLING GASOLINE WHILE VEHICLE WAS PARKED IN MY GARAGE, I REMOVED THE OUTER BODY PARTS AND DISCOVERED THAT THE FLANGE WHERE THE HIGH PRESSURE FUEL LINE IS ATTACHED TO THE FUEL TANK HAS SEVERAL CRACKS RADIATING OUT FROM WHERE THE FITTING IS SCREWED INTO THE FLANGE. GASOLINE HAD BEEN LEAKING OUT AND ACCUMULATING ON THE FLANGE. FUEL COULD HAVE LEAKED ONTO THE EXHAUST WHILE RIDING, RESULTING IN A POSSIBLE FIRE. APPARENTLY, THIS PROBLEM IS KNOWN BY BMW, AS IT REPORTED ON SEVERAL WEBSITES. *TR

NHTSA ID

10493320

Incident

Jan 17, 2013

Mileage

28,055 mi

I HAVE DETECTED THE SMELL OF RAW GAS COMING FROM THE DRIVER'S SIDE OF MY MOTORCYCLE. I REMOVED THE SIDE COVER AND TANK SHROUD TO DISCOVER THAT THE PLASTIC FLANGE THAT CONNECTS THE FUEL PUMP TO THE FUEL LINE HAS CRACKED AND IS LEAKING A FINE MIST OF FUEL OUT INTO THE ATMOSPHERE AND AT WORST CASE ONTO THE LEFT CYLINDER OF THE MOTORCYCLE. IT SEEMS THAT THIS IS A PROBLEM PREVALENT TO THESE MOTORCYCLES AND COULD CAUSE THE VEHICLE TO BURST INTO FLAMES IF LEFT UNATTENDED. *TR

NHTSA ID

10492118

Incident

Jan 3, 2013

Mileage

34,455 mi

FAILURE FOUND DURING SCHEDULED SERVICE WORK. FAILURE OF THE FUEL PUMP HOUSING HIGH-PRESSURE FUEL QUICK DISCONNECT REINFORCEMENT FLANGE CRACKS UNDER HIGH PRESSURE.WITH RISK OF LEAKING FUEL, IS EXHAUSTED ON THE RIDERS LEFT LEG, CREATING SIGNIFICANT RISK FOR THE RIDER EVEN AFTER DISMOUNTING THE VEHICLE. CONSEQUENCES OF FAILURE THE COMBINATION OF HIGH FUEL PRESSURE AND NEGLIGENT DESIGN CREATE SUBSTANTIAL RISK FOR RIDERS OF THE IMPACTED VEHICLES. THERE ARE MULTIPLE NEGATIVE CONSEQUENCES OF THIS FAILURE.1. RIDERS BECOME FUEL SOAKED AS FUEL LEAKS ON TO THE RIDERS LEFT LEG. 2. FUEL VAPORS, HEATED BY THE EXHAUST PIPE BECOME EXTREMELY VOLATILE AND COULD LEAD TO A FIRE AND/OR EXPLOSION. 3. FUEL VAPORS RISING FROM THE FAIRING AND EXITING THE TOP OF THE FAIRING BETWEEN THE INSTRUMENT PANEL AND FUEL TANK, ARE BLOWN BY AIRFLOW INTO THE RIDERS FACE. THE CARCINOGENIC ASPECTS OF FUEL INHALATION ARE DOCUMENTED. PRELIMINARY ANALYSIS EXAMINATION OF THE FUEL PUMP ASSEMBLY SUGGESTS THAT THE HIGH-PRESSURE FUEL QUICK DISCONNECT REINFORCEMENT FLANGE WAS INADEQUATELY DESIGNED FOR THE FUEL PUMP OUTLET PRESSURES. BMW'S CHOICE OF A NON-METALLIC (COMPOSITE) PUMP HOUSING COMBINED WITH A COMPOSITE HIGH-PRESSURE DISCONNECT FITTING WAS UNWISE AND THE FAILURE MECHANISM IS OBVIOUS. HIGH PUMP PRESSURE EXPANDS THE COMPOSITE HIGH-PRESSURE FITTING CAUSING IT TO READILY LOAD THE FUEL PUMP HIGH-PRESSURE QUICK DISCONNECT FLANGE. OVER TIME, PRESSURE CYCLING CAUSES THE QUICK DISCONNECT REINFORCEMENT FLANGE TO CRACK ALLOWING FUEL TO LEAK. *TT

NHTSA ID

10459207

Incident

May 17, 2012

Mileage

39,500 mi

FUEL PRESSURE CONTROL MODULE FAILED WITHOUT WARNING LEAVING ME STRANDED IN THE MIDDLE OF THE FREEWAY. PART WAS REPLACED UNDER WARRANTY BUT FAILED AGAIN, LEAVING ME STRANDED AGAIN, ON JUNE 7, 2011. WAS TOLD BY THE DEALER THAT THIS WAS 'RARE'. SEEMS LIKE AN UNSAFE CONDITION TO ME. *TR

NHTSA ID

10454396

Incident

Oct 16, 2009

Mileage

14,202 mi

I WAS DRIVING DOWN THE HIGHWAY COMING HOME FROM WORK, I SMELLED SOMETHING BURNING, I WASN'T SURE IF IT WAS ME OR ANOTHER VEHICLE. I PULLED OVER AND NOTICED SMOKE COMING OFF MY EXHAUST PIPE, MORE INSPECTION SHOWED IT COMING FROM MY CONNECTION ON TOP OF MY FUEL PUMP, GAS WAS LEAKING FROM THE CONNECTION AND DOWN ON TO MY EXHAUST PIPE. I GOT IT HOME AND STARTED LOOKING INTO THE ISSUE AND FOUND MANY MORE PEOPLE WITH THE SAME PROBLEM. THIS IS A VERY DANGEROUS ISSUE AND IF IT ISN'T A RECALL NOW IT SHOULD BE. I WILL CALL TUESDAY WHEN MY LOCAL DEALER OPENS. *TR

NHTSA ID

10453738

Incident

Mar 20, 2012

Mileage

22,230 mi

FAILURE OF THE FUEL PUMP HOUSING HIGH-PRESSURE FUEL QUICK DISCONNECT REINFORCEMENT FLANGE CRACKS UNDER HIGH PRESSURE CYCLING AND LEAKS, SENDING RAW FUEL DOWN THE LEFT FAIRING IN CLOSE PROXIMITY OF THE VEHICLES LEFT EXHAUST PIPE AND IGNITION SYSTEM COMPONENTS. THE VEHICLES FAIRING EFFECTIVELY CAPTURES THE FUEL VAPORS CREATING A SIGNIFICANT RISK FOR FIRE. PRELIMINARY ANALYSIS EXAMINATION OF THE FUEL PUMP ASSEMBLY SUGGESTS THAT THE HIGH-PRESSURE FUEL QUICK DISCONNECT REINFORCEMENT FLANGE WAS INADEQUATELY DESIGNED FOR THE FUEL PUMP OUTLET PRESSURES. BMW'S CHOICE OF A NON-METALLIC (COMPOSITE) PUMP HOUSING COMBINED WITH A COMPOSITE HIGH-PRESSURE DISCONNECT FITTING WAS UNWISE AND THE FAILURE MECHANISM IS OBVIOUS. HIGH PUMP PRESSURE EXPANDS THE COMPOSITE HIGH-PRESSURE FITTING CAUSING IT TO READILY LOAD THE FUEL PUMP HIGH-PRESSURE QUICK DISCONNECT FLANGE. OVER TIME, PRESSURE CYCLING CAUSES THE QUICK DISCONNECT REINFORCEMENT FLANGE TO CRACK ALLOWING FUEL TO LEAK. *TR

NHTSA ID

10445077

Incident

Jan 24, 2012

Mileage

35,000 mi